Electrical connector with modular grooves

ABSTRACT

An electrical connector including a plug and receptacle member comprising a plurality of annular cylinders coaxially and telescopically interdisposed over one another. A plurality of flat electrical contacts are disposed in grooves provided in the cylinders parallel to the longitudinal axis of the plug and receptacle members for interconnecting a plurality of electrical conductors. Retaining members are integrally formed in the grooves to prevent axial movement of the flat contacts in the plug and receptacle members, and each of the contacts is provided with a V-shaped portion near its free end which interengages with a corresponding portion of mating contacts of the connector to prevent disengagement of the plug from the receptacle. The cylinders which form the plug and receptacle members may also be provided with a plurality of radially outwardly extending rib members having semi-circular projections integrally formed thereon which are received in correspondingly shaped recesses on the internal surfaces of the cylinders to prevent circular movement of the cylinders with respect to each other.

limited States Patent [191 Grundiest [451 Aug. 20, 1974 1 1 ELECTRICAL CONNECTOR WITH MODULAR GROOVES [76] Inventor: Michael Grundfest, 99-41 64th Ave, Forest Hills, NY. 11374 [22] Filed: May 11, 1972 [21] Appl. No.: 252,439

[52] US. Cl 339/186 M, 339/47 R, 339/210 M [51] Int. Cl H011 13/64 [58] Field of Search 339/47 R, 49 R, 176 R,

339/176 M, 177, 193,194, 196,198 C, 206-210, 5 M, 8 P, 200

[56] References Cited UNITED STATES PATENTS 453,225 6/1891 Wheeler 339/49 R X Primary Examiner-Bobby R. Gay Assistant ExaminerLawrence J. Staab Attorney, Agent, or FirmAllison C. Collard 5 7] ABSTRACT An electrical connector including a plug and receptacle member comprising aplurality of annular cylinders coaxially and telescopically interdisposed over one another. A plurality of flat electrical contacts are disposed in grooves provided in the cylinders parallel to the longitudinal axis of the plug and receptacle members for interconnecting a plurality of electrical conductors. Retaining members are integrally formed in the grooves to prevent axial movement of the flat contacts in the plug and receptacle members, and each of the contacts is provided with a V-shaped portion near its free end which interengages with a corresponding portion of mating contacts of the connector to prevent disengagement of the plug from the receptacle. The cylinders which form the plug and receptacle members may also be provided with a plurality of radially outwardly extending rib members having semi-circular projections integrally formed thereon which are received in correspondingly shaped recesses on the internal surfaces of the cylinders to prevent circular movement of the cylinders with respect to each other.

4 Claims, 10 Drawing Figures PAIENIEnauczozsn sum 2 w 2 ELECTRICAL CONNECTOR WITH MODULAR GROOVES The present invention relates to electrical connectors, and in particular, to a multi-level multi-contact electrical connector for interconnecting a plurality of electrical conductors disposed in a cable, harness or the like.

In conventional electrical connectors, the apertures formed therein through which the contacts of the connector are disposed are completely enclosed by the electrical insulation comprising the connector. The shape of the apertures in the connector is limited by molding techniques, and the apertures retain the electrical contacts therein only in directions which are perpendicular to the longitudinal axes of the contacts. In some connectors, the contacts may be restrained from movement in one axial direction, but this entails the addition of retaining parts to the connector. Furthermore, conventional electrical connector contacts define the shape and location of the grooves in the connector and are supported only at their ends, and a precision made conventional electrical connector is manufactured only at a considerably higher manufacturing cost than other connectors, so that their use is limited to special applications where the higher cost can be justified by the application.

Accordingly, the present invention provides an electrical connector which overcomes the disadvantages of conventional electrical connectors. The connector comprises a plug member and a receptacle member, each consisting of a plurality of annular-shaped cylinders of different diameters disposed coaxially and telescopically over each other and arranged in order of decreasing diameter in a pyramid shape. One surface of each of the cylinders is provided with a plurality of grooves for receiving electrical contacts and securing them parallel to the longitudinal axis of the plug and receptacle members. The cylinders are constructed of electrical insulation material, and each of the contacts secured in the plug and receptacle members are separated from adjacent contacts by the cylinders. The electrical contacts also have a V-shaped section for engaging a correspondingly shaped section of another oppositely disposed electrical contact when the plug member is inserted into the receptacle member. The V-shaped sections interengage, and secure the plug and receptacle members together to prevent accidental disengaging of the plug and receptacle members. Each of the contacts are secured in the grooves provided in the cylinders by adjacent cylinders disposed over the ends of the contacts.

With the design of the electrical connector of the present invention, it is possible to mold the components of the connector which secure the electrical contacts therein as an integral part of the grooves provided in ten material during the molding operation. Stress distortion which occurs during the cooling process is also minimized.

It is, therefore, an object of the present invention to provide an electrical connector in which the electrical contacts thereof cannot move axially in the connector.

It is a further object of the present invention to provide an electrical connector whose electrical performancecapabilities are not restricted by tool design and molding technique limitations.

It is a further object of the present invention to provide an electrical connector which is simple in design, easy to manufacture and efficient and reliable in operation.

Other objects and features of the present invention will become apparent from the following detailed description taken in connection with the accompanying drawings which disclose the embodiments of the invention. It is to be understood, however, that the drawings are designed for the purpose of illustration only, and are not intended as a definition of the limits and scope of the invention.

In the drawings, wherein similar reference numerals denote similar elements throughout the several views:

FIG. 1 is a front perspective view of the plug member of an electrical connector constructed in accordance with the present invention;

FIG. 2 is a cross-sectional side view of the plug member of the electrical connector, taken along section 10-10 of FIG. 1;

FIG. 3 is a cross-sectional side view of a receptacle member for an electrical connector constructed in accordance with the present invention;

FIG. 4 is a partial, exploded perspective view of an electrical contact of the plug member shown in FIG. 2;

FIG. 5 is an exploded, partial perspective view of an electrical contact of the receptacle member shown in FIG. 3;

FIG. 6 is a cross-sectional side view of another embodiment of an electrical connector constructed in accordance with the present invention;

FIG. 7 is a partial cross-sectional end view of the connector shown in FIG. 6;

FIG. 8 is a partial cross-sectional end view of another embodiment of an electrical connector constructed in accordance with the present invention;

FIG. 9 is an exploded perspective view of the electrical connector shown in FIG. 8; and

FIG. 10 is a perspective view of still another embodiment of an electrical connector constructed in accordance with the present invention.

Referring to the drawings, specifically to FIGS. 1-3, there is shown a plug member 10 of the electrical connector of the present invention which comprises a plurality of annular-shaped cylinders 11 which are telescopically and coaxially disposed over one another to form a pyramid-shaped structure. A plurality of elongated, flat electrical contacts 12 are disposed in longitudinal grooves 13 in each of the cylinders parallel to the longitudinal axis of the plug member. Each of contacts 12 is provided with a V-shaped portion 14 at its unsecured end, and has the end thereof bent upwardly at an acute angle with respect to the surfaces of cylinders 11. Contacts 12 are electrically connected to a plurality of electrical conductors 15. A solid cylindrical member 16 comprises the front end of the plug member, and is provided with a key cylinder 17 for guiding the plug member into the receptacle member in a predetermined position.

Receptacle member 16 is also comprised of a plurality of annular-shaped cylinders 17 which are concentrically and telescopically disposed over each other in a pyramid shape. A plurality of flat electrical contacts 18 are disposed between cylinders 17 in grooves 19. Each contact has a V-shaped portion 20 for receiving V- shaped portion 14 on contacts 12 of plug member when the plug member is inserted into the receptacle member of the connector. V-shaped portions and 14 interengage so as to prevent accidental disengagement of the plug and receptacle members. Contacts 18 are disposed on the inside surfaces of cylinder 18, and the edges thereof are bent inwardly towards the axis of the receptacle member at an acute angle with respect to the inside surfaces of cylinders 17. A key slot 21 is provided in solid cylinder 22, which comprises the forward portion of the receptacle member. The length of contacts 12 and 18 are such that the contacts will not engage one another until key cylinder 17 is slidably disposed in key slot 21 when the plug is inserted in the receptacle member. It should be noted that the construction of cylinders 17 and 22 may be such that the key slot is located in cylinder 16 and the key cylinder is formed with cylinder 22.

When plug member 10 is slidably disposed in receptacle member 16, the ends of contacts 12 and 18 engage each other and the V-shaped portions thereof interlock so as to secure the plug in the receptacle. In order to remove the plug from the receptacle, strong manual force must be exerted on the receptacle and plug to disengage the contacts. The V-shaped portions of the contacts prevent any accidental disengagement of the plug member from the receptacle member.

Contacts 12 and 18 are provided with a polygonal shaped notch 24 along one edge thereof, and a U- shaped end portion which extends downwardly into the grooves provided in the plug and receptacle members of the electrical connector. Grooves l3 and 19 include a rear rectangular shaped portion, and a raised portion which includes an abutment member 26 having a shape corresponding to notch 24 provided in the electrical contacts. The elevated portion of the groove, and abutment members 26, prevent axial movement of the electrical contacts in the grooves, and an inclined forward portion 27 provided in each groove allows the electrical contacts to bend within each groove, as shown by the dotted lines in FIG. 5. Each of the contacts is secured in the groove by the adjoining cylinders. In FIG. 4, the outer surfaces of cylinders 11 engage the planar top surface of contact 12 and retain it in the groove, and in FIG. 5, the inner surfaces of cylinders 17 engage the flat top of contacts 18 and retain the contacts in the groove. Cylinders 11 and 17 are constructed of electrically non-conductive insulation material, and may be affixed to each other by any suitable fastening means, such as by insulated rivets or bolts.

In FIGS. 6 and 7, another embodiment of an electrical connector is shown. In this embodiment, the plug and receptacle members comprise a plurality of coaxially disposed cylinders 23 which have a plurality of Iongitudinal grooves 24 disposed therein for receiving the electrical contacts. In this embodiment, the cylinders are not telescopically arranged, and the plug and receptacle members are cylindrical in shape. Grooves 24 are the same as grooves 13 and 19 described in the above embodiments, and the electrical contacts used therein are the same as those previously described.

Another embodiment of the electrical connector is shown in FIGS. 8 and 9. This embodiment is similar to that described with respect to FIGS. 6 and 7, and comprises a plurality of concentrically disposed cylinders 26 having a plurality of elongated rib members 27 integrally formed on the periphery of the outer surface thereof. Each of ribs 27 has a semi-circular projection 28 integrally formed on the upper surface thereof which is received in a correspondingly shaped slot 29 disposed on the inside surfaces of cylinders 26. Ribs 27 and projections 28 prevent circular movement of cylinders 26. Grooves 30 receive the electrical contacts of the connector, and are the same as those described in the previous embodiments.

FIG. 10 shows still anotherembodiment of the connector described in FIGS. 6 and 7. The connector plug and receptacle members comprise a plurality of cylinders 31 having key slots 32 disposed on the inner surfaces thereof and projection members 33 integrally formed on the outer surface thereof so that when cylinders 31 are interdisposed, as illustrated in FIG. 6, members 33 are slidably disposed in key slots 32 to prevent circular movement of the cylinders with respect to each other. In this embodiment, as well as in the embodiments of FIGS. 6 and 7, and FIGS. 8 and 9, the cylinders may be telescopically arranged.

The materials used to construct the electrical connector of the present invention may be of any conventional type. For example, the electrically nonconductive insulation materials may be plastic, and the electrically conductive materials may be copper alloy.

The connector of the present invention can be used as a solderless connector wherein the contacts are initially crimpecl to the conductors, and then inserted into the contact receiving apertures of the connector.

While only several embodiments of the present invention have been shown and described, it will be obvious to those persons of ordinary skill in the art that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention.

What is claimed is:

1. A multi-contact electrical connector comprising:

a plug comprising a plurality of cylindrically shaped telescoped members coaxially disposed over each other, said members being of different diameter and interdisposed in the order of decreasing diameter, and including a plurality of spaced-apart grooves disposed parallel to the longitudinal axis of said plug about the periphery of said plurality of members, said plug including a forwardly projecting key cylinder;

a receptacle comprising a plurality of cylindricallyshaped telescoped members coaxially disposed over each other, said members being of different diameters and interdisposed in the order of decreasing diameter and including a plurality of spaced apart longitudinal grooves disposed in said annular-shaped members about the periphery thereof parallel to the longitudinal axis of said receptacle, said receptacle including a recessed cylindrical key slot corresponding to said key, corresponding grooves of said plug and receptacle members being in alignment when the key cylinder is received with said key slot;

plurality of elongated flat electrical contacts disposed in the grooves of said cylindrically shaped plug, said plug contacts each including a V-shaped portion, and an end portion adjacent the V-shaped portion and bent to an acute angle with respect to the surface of its associated plug member; plurality of elongated flat electrical contacts disposed in the grooves of said cylindrically-shaped receptacle, said receptacle contacts each including a V-shaped portion, and an end portion adjacent the V-shaped portion and bent at an acute angle with respect to the surface of its associate receptacle members;

retaining means integrally formed in the grooves of said plug and receptacle members and engaging said contacts for preventing axial movement of the contacts in said grooves, said retaining means maintaining the end portions of said contacts slightly recessed from the edges of their associated plug and receptacle members, so that the end portions are separated from each other by said members, said V-shaped portions simultaneously interengaging when the plug is inserted into the receptacle to prevent disengagement of said contacts from each other; and

plurality of radially outwardly extending rib members, disposed on the outer surfaces of said cylindrical members, parallel to the longitudinal axes thereof, and including semi-circular projection members, integrally formed with said rib members, and a plurality of elongated semicircular grooves, disposed on the inside surfaces of said members parallel to the longitudinal axes thereof, for slidably receiving said semi-circular projections integrally formed on said rib members, and thereby preventing rotational movement of said members with respect to each other.

A multi-contact electrical connector comprising:

plug comprising a plurality of cylindrically shaped telescoped members coaxially disposed over each other, said members being of different diameter and interdisposed in the order of decreasing diameter, and including a plurality of spaced-apart grooves disposed parallel to the longitudinal axis of the plug about the periphery of said plurality of members, said plug including a forwardly projecting key cylinder;

receptacle comprising a plurality of cylindricallyshaped telescoped members coaxially disposed over each other, said members being of different diameters and interdisposed in theorder of decreasing diameter and including a plurality v of spaced apart longitudinal grooves disposed in said annular-shaped members about the periphery thereof parallel to the longitudinal axis of said receptacle, said receptacle including a recessed cylindrical key slot corresponding to said key, corresponding grooves of said plug and receptacle members being in alignment when the key cylinder is received with said key slot;

a plurality of elongated flat electrical contacts disposed in the grooves of said cylindrically shaped plug, said plug contacts each including a V-shaped portion, and an end portion adjacent the V-shaped portion and bent to an acute angle with respect to the surface of its associated plug member;

a plurality of elongated fiat electrical contacts disposed in the grooves of said cylinderically-shaped receptacle, said receptacle contacts each including a V-shaped portion, and an end portion adjacent the V-shaped portion and bent at an acute angle with respect to the surface of its associated receptacle member;

retaining means integrally formed in the grooves of said plug and receptacle members and engaging said contacts for preventing axial movement of the contacts in said grooves, said retaining means maintaining the end portions of said contacts slightly recessed from the edges of their associated plug and receptacle members, so that the end portions are separated from each other by said members, said V-shaped portions simultaneously interengaging when the plug is inserted into the receptacle to prevent disengagement of said contacts from each other; and

said cylindrical members each further comprising a pair of rectangular-shaped recesses disposed in one end thereof on the inner surfaces of said members opposite each other, and a pair of rectangularshaped guide members, integrally formed with said members and disposed on the outer surfaces thereof opposite said recesses, said rectangularshaped members being disposed in said recesses provided of the inside surfaces of said members for preventing rotational movement of said members with respect to each other.

3. A multilayer shell for a plug or receptacle of a multi-contact electrical connector comprising:

a plurality of cylindrically shaped telescoped memretaining means integrally formed in the grooves of said cylindrically-shaped member and engaging said contacts for preventing axial movement thereof, said retaining means maintaining the bent end portions of said contacts slightly recessed from the edge of their associated cylindrical members so that the end portions of said contacts are separated from each other by said cylindrical members; and

a plurality of radially outwardly extending rib members disposed on the outer surfaces of said cylindrical members, parallel to the longitudinal axes thereof, and including semi-circular projection members, integrally formed with said rib members, and a plurality of elongated semi-circular grooves,

ti-contact electrical connector comprising:

a plurality of cylindrically shaped telescoped members coaxially disposed over each other, said members being of different diameter and interdisposed in the order of decreasing diameter and including I a plurality of spaced-apart grooves disposed parallel to the longitudinal axis of said plug about the periphery of said cylindrical shaped members;

a plurality of elongated flat electrical contacts disposed in the grooves of said cylindrically shaped member, said contacts each including a V-shaped portion, and an end portion adjacent to the V- shaped portion and bent up at an acute angle with respect to the surface of its associated cylindrically shaped member;

retaining means integrally formed in the grooves of said cylindrically shaped member and engaging said contacts for preventing axial movement thereof, said retaining means maintaining the bent end portions of said contacts slightly recessed from the edge of their associated cylindrical members so that the end portions of said contacts are separated from each other by said cylindrical members; and

with respect to each other. 

1. A multi-contact electrical connector comprising: a plug comprising a plurality of cylindrically shaped telescoped members coaxially disposed over each other, said members being of different diameter and interdisposed in the order of decreasing diameter, and including a plurality of spaced-apart grooves disposed parallel to the longitudinal axis of said plug about the periphery of said plurality of members, said plug including a forwardly projecting key cylinder; a receptacle comprising a plurality of cylindrically-shaped telescoped members coaxially disposed over each other, said members being of different diameters and interdisposed in the order of decreasing diameter and including a plurality of spaced apart longitudinal grooves disposed in said annularshaped members about the periphery thereof parallel to the longitudinal axis of said receptacle, said receptacle including a recessed cylindrical key slot corresponding to said key, corresponding grooves of said plug and receptacle members being in alignment when the key cylinder is received with said key slot; a plurality of elongated flat electrical contacts disposed in the grooves of said cylindrically shaped plug, said plug contacts each including a V-shaped portion, and an end portion adjacent the V-shaped portion and bent to an acute angle with respect to the surface of its associated plug member; a plurality of elongated flat electrical contacts disposed in the grooves of said cylindrically-shaped receptacle, said receptacle contacts each including a V-shaped portion, and an end portion adjacent the V-shaped portion and bent at an acute angle with respect to the surface of its associate receptacle members; retaining means integrally formed in the grooves of said plug and receptacle members and engaging sAid contacts for preventing axial movement of the contacts in said grooves, said retaining means maintaining the end portions of said contacts slightly recessed from the edges of their associated plug and receptacle members, so that the end portions are separated from each other by said members, said V-shaped portions simultaneously interengaging when the plug is inserted into the receptacle to prevent disengagement of said contacts from each other; and a plurality of radially outwardly extending rib members, disposed on the outer surfaces of said cylindrical members, parallel to the longitudinal axes thereof, and including semicircular projection members, integrally formed with said rib members, and a plurality of elongated semicircular grooves, disposed on the inside surfaces of said members parallel to the longitudinal axes thereof, for slidably receiving said semicircular projections integrally formed on said rib members, and thereby preventing rotational movement of said members with respect to each other.
 2. A multi-contact electrical connector comprising: a plug comprising a plurality of cylindrically shaped telescoped members coaxially disposed over each other, said members being of different diameter and interdisposed in the order of decreasing diameter, and including a plurality of spaced-apart grooves disposed parallel to the longitudinal axis of the plug about the periphery of said plurality of members, said plug including a forwardly projecting key cylinder; a receptacle comprising a plurality of cylindrically-shaped telescoped members coaxially disposed over each other, said members being of different diameters and interdisposed in the order of decreasing diameter and including a plurality of spaced apart longitudinal grooves disposed in said annular-shaped members about the periphery thereof parallel to the longitudinal axis of said receptacle, said receptacle including a recessed cylindrical key slot corresponding to said key, corresponding grooves of said plug and receptacle members being in alignment when the key cylinder is received with said key slot; a plurality of elongated flat electrical contacts disposed in the grooves of said cylindrically shaped plug, said plug contacts each including a V-shaped portion, and an end portion adjacent the V-shaped portion and bent to an acute angle with respect to the surface of its associated plug member; a plurality of elongated flat electrical contacts disposed in the grooves of said cylinderically-shaped receptacle, said receptacle contacts each including a V-shaped portion, and an end portion adjacent the V-shaped portion and bent at an acute angle with respect to the surface of its associated receptacle member; retaining means integrally formed in the grooves of said plug and receptacle members and engaging said contacts for preventing axial movement of the contacts in said grooves, said retaining means maintaining the end portions of said contacts slightly recessed from the edges of their associated plug and receptacle members, so that the end portions are separated from each other by said members, said V-shaped portions simultaneously interengaging when the plug is inserted into the receptacle to prevent disengagement of said contacts from each other; and said cylindrical members each further comprising a pair of rectangular-shaped recesses disposed in one end thereof on the inner surfaces of said members opposite each other, and a pair of rectangular-shaped guide members, integrally formed with said members and disposed on the outer surfaces thereof opposite said recesses, said rectangular-shaped members being disposed in said recesses provided of the inside surfaces of said members for preventing rotational movement of said members with respect to each other.
 3. A multilayer shell for a plug or receptacle of a multi-contact electrical connector comprising: a plurality of cylindrically shaped telescoped members coaxially disposed over eAch other, said members being of different diameter and interdisposed in the order of decreasing diameter and including a plurality of spaced-apart grooves disposed parallel to the longitudinal axis of said plug about the periphery of said cylindrically shaped members; a plurality of elongated flat electrical contacts disposed in the grooves of said cylindrically shaped member, said contacts each including a V-shaped portion, and an end portion adjacent to the V-shaped portion and bent up at an acute angle with respect to the surface of its associated cylindrically shaped member; retaining means integrally formed in the grooves of said cylindrically-shaped member and engaging said contacts for preventing axial movement thereof, said retaining means maintaining the bent end portions of said contacts slightly recessed from the edge of their associated cylindrical members so that the end portions of said contacts are separated from each other by said cylindrical members; and a plurality of radially outwardly extending rib members disposed on the outer surfaces of said cylindrical members, parallel to the longitudinal axes thereof, and including semi-circular projection members, integrally formed with said rib members, and a plurality of elongated semi-circular grooves, disposed on the inside surfaces of said cylindrical members parallel to the longitudinal axes thereof, for slidably receiving said semi-circular projections integrally formed on said rib members and thereby preventing rotational movement of said cylinders with respect to each other.
 4. A multilayer shell for a plug or receptacle of a multi-contact electrical connector comprising: a plurality of cylindrically shaped telescoped members coaxially disposed over each other, said members being of different diameter and interdisposed in the order of decreasing diameter and including a plurality of spaced-apart grooves disposed parallel to the longitudinal axis of said plug about the periphery of said cylindrical shaped members; a plurality of elongated flat electrical contacts disposed in the grooves of said cylindrically shaped member, said contacts each including a V-shaped portion, and an end portion adjacent to the V-shaped portion and bent up at an acute angle with respect to the surface of its associated cylindrically shaped member; retaining means integrally formed in the grooves of said cylindrically shaped member and engaging said contacts for preventing axial movement thereof, said retaining means maintaining the bent end portions of said contacts slightly recessed from the edge of their associated cylindrical members so that the end portions of said contacts are separated from each other by said cylindrical members; and said cylindrical members each further comprising a pair of rectangular-shaped recesses disposed in one end thereof on the inner surfaces of said members opposite each other, and a pair of rectangular-shaped guide members, integrally formed with said members and disposed on the outer surfaces thereof opposite said recesses, said rectangular-shaped members being disposed in said recesses provided on the inside surfaces of said members for preventing rotational movement of said members with respect to each other. 